Solar tracker system and method of making

ABSTRACT

A solar tracker system and method for making are disclosed. The system may comprise a solar panel array assembly having at least two attachments, a support anchor assembly for attaching to a surface and having at least two attachments, and a support structure including a plurality of elongated support rods for securing the array assembly above the support anchor assembly. Each support rod may be attached at one end to one of the attachments of the solar panel array and attached at the other end to one of the attachments of the support anchor assembly.

FIELD OF THE INVENTION

The present invention relates in general to a system and method formaking a solar tracker system. It more particularly relates to a systemand method for making a robust solar tracker system that is easy andinexpensive to install.

BACKGROUND ART

There is no admission that the background art disclosed in this sectionlegally constitutes prior art.

Conventional solar trackers employ controllably moveably mounted solarpanels to expose them continuously to the path of the sun boththroughout the day and throughout the year. For example, reference maybe made to U.S. Pat. No. 6,058,930.

Such solar trackers may be prohibitively expensive to install on a largecommercial scale primarily due to the installation cost of largeconcrete footing anchorage or the like. Also, conventional trackers havenot been entirely satisfactory for some applications due to theirinability to adequately withstand adverse weather conditions such ashigh winds. In this regard, conventional solar tracking systemstypically employ a single point of connection from the anchorage to thelarge projected area of the solar panel array.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of this invention and the manner of attaining them willbecome apparent, and the invention itself will be best understood byreference to the following description of certain embodiments of theinvention taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a diagrammatic view of a solar tracker system according to anembodiment of the present invention;

FIG. 2 is a pictorial view of a solar tracker system attached to arooftop according to an embodiment of the present invention;

FIGS. 3 is a front pictorial view of the solar tracker system of FIG. 2;

FIG. 4 is a side pictorial view of the solar tracker system of FIG. 2;

FIG. 5 is an enlarged view of the underside of the solar panel array ofthe solar tracker system of FIG. 2 showing the axes of rotation;

FIG. 6 is a pictorial view of a solar tracker system having anchors thatscrew into the ground;

FIGS. 7 and 8 are pictorial views of another embodiment of a solartracker system according to the present invention;

FIG. 9 is a diagrammatic view of the tracker controller of the solartracker system of FIG. 1; and

FIG. 10 is a pictorial view of solar tracker system having a singleanchoring point for attaching the system to the ground.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS OF THE INVENTION

It will be readily understood that the components of the embodiments asgenerally described and illustrated in the drawings herein, could bearranged and designed in a wide variety of different configurations.Thus, the following more detailed description of the embodiments of thesystem, components and method of the present invention, as representedin the drawings, is not intended to limit the scope of the invention, asclaimed, but is merely representative of the embodiments of theinvention.

A solar tracker system and method for making it are disclosed. Byutilizing an embodiment of the invention, incident solar radiation maybe more efficiently and effectively collected throughout the day andthroughout the year by a system that is relatively inexpensive andsimple to install. The embodiments of the present invention arestructurally strong and are able to withstand severe weather conditionsincluding high winds in a more secure manner.

In accordance with certain embodiments of the present invention, thereis provided a solar tracker system, which may comprise a solar panelarray assembly having at least two attachments for mounting the systemon a surface such as the ground, a structure or other. A support anchorassembly for attaching to the surface and having at least twoattachments, and a support structure including a plurality of elongatedsupport rods for securing the array assembly above the support anchorassembly. Each support rod may be attached at one end to one of theattachments of the solar panel array and attached at the other end toone of the attachments of the support anchor assembly. The number ofsupport rods connected to each attachment of the solar panel arrayassembly may equal the number of attachments of the support anchorassembly, and the number of support rods connected to each attachment ofthe support anchor assembly may equal the number of attachments of thesolar panel assembly.

In accordance with another embodiment of the present invention, there isprovided a solar tracker system for mounting on a surface. The systemmay comprise a solar panel array assembly having at least twoattachments at least three anchors for attaching to the surface, and asupport structure including a plurality of elongated support rods forsecuring the array assembly above the support anchor assembly. Eachsupport rod may attach at one end to one of the attachments of the solarpanel array and attach at the other end to one of the anchors. Thenumber of support rods connected to each attachment of the solar panelarray assembly may equal the number of anchors, and the number ofsupport rods connected to each anchors may equal the number ofattachments of the solar panel assembly.

In accordance with yet another embodiment of the present invention,there is provided a solar tracker system for mounting on a surface. Thesystem may comprise a solar panel array assembly having a rotatingsupport, a support anchor assembly for attaching to the surface andhaving a rotating support, and a support structure disposed between therotating support of the solar panel array assembly and the rotatingsupport of the support anchor assembly to provide two axes of movementof the solar panel array assembly relative to the support anchorassembly. The support structure may include a plurality of elongatedsupport rods configured in the shape of a tetrahedron for securing thearray assembly above the support anchor assembly.

In accordance with yet another embodiment of the present invention,there is provided a solar tracker system for mounting to an anchor in asurface. The system may include a support structure having at leastthree legs, a solar panel array assembly mounted to the supportstructure, and an anchoring point disposed on the support structure andadapted for attaching to the anchor in the surface.

Referring to FIG. 1, a solar tracker system 10 is shown for collectingincident solar radiation throughout the day and throughout the year. Thesolar tracker system 10 may include a solar panel array assembly 12having a plurality of solar panels 13 and a tracker controller 16 forcontrolling the position of the solar panel array assembly 12 and fortransferring the DC power generated by the solar panel array assembly 12to a DC bus 14. The DC power may range from 300 to 1,200 VDC. The DC bus14 may be connected to a storage device (not shown) containing one ormore batteries or to a converter (not shown) for converting the DC powerto AC power. In brief, the solar panel array assembly 12 as controlledby tracker controller 16 may daily track the sun from approximatelysunrise to sunset for collecting incident solar radiation and convertingit into DC power for immediate use or storage. Also, the trackercontroller 16 selectively energizes East/West (E/W) and North/South(N/S) motors 75 and 70, respectively, to move the solar panel arrayassembly 12 along a pair of axes using signals from East/West (E/W) andNorth/South (N/S) inclinometers 81 and 83, respectively, as hereinafterexplained in greater detail.

Referring now to FIG. 9, the tracker controller 16 is shown in moredetail. The tracker controller 16 may include a DC combiner forreceiving DC power inputs from each of the solar panels. Most of the DCpower may be placed on a DC power bus that may be outputted from thecontroller 16 to a DC power bus connected to storage devices or aconverter. A portion of the DC power may be provided to a DC/DCconverter and power supply 19 to produce and supply suitable DC power tothe controller 16. A control/drive module 22 may be provided in thecontroller 16 to control the position of the solar panel array assembly.The control/drive module 22 may receive the suitable DC power from thepower supply 19, an input from the altitude inclinometer 83 (N/Sinclinometer) (FIG. 1), and an input from the azimuth inclinometer 81(E/W inclinometer) (FIG. 1); and provide drive outputs to the altitudemotor 70 (N/S motor) (FIG. 1) and the azimuth motor 75 (E/W motor) (FIG.1). The control/drive module 22 may include firmware and/or softwarethat utilize the inclinometer inputs to appropriately drive the motorsto enable the solar panel array assembly to track the position of thesun throughout the day and throughout the year. A USB interface 24 and awireless communication module 26 may also be provided in the controller16 to provide access to the control/drive module 22 using a laptopcomputer 28 or other suitable device. The control/drive module 22 mayprovide outputs that control one or more external displays 15 (FIG. 1)and status LEDs.

Referring now to FIGS. 2 through 5, the solar panel array assembly 12may be moveably supported from a mounting surface by a stationarysupport structure 18 having a plurality of support rods or struts 21,23, 27, 29, 31 connected between the solar panel array assembly 12 and aplurality of anchors 34, 36, 38 for supporting the solar panel arrayassembly 12 above the mounting surface in a convenient and secure mannerto withstand adverse weather conditions including high winds. One end ofsupport rods 21 and 29 may be connected together at a point 30 with aconnector 76, and one end of support rods 23, 27, and 31 may beconnected together at a point 32 with a connector 78. When the mountingsurface is a rooftop 45, the anchors 34, 36, 38 may be attached tosupport beams 41, 43 of the rooftop 45 using a plurality of fasteners47, such as bolts and nuts, as shown in FIG. 2. When the mountingsurface is the ground 81, helical screw anchor 82, 83, 85 may beutilized by screwing them directly into the ground 81 as shown in FIG.6.

The arrangement of support rods or struts provides the system 10 with astructurally strong configuration to enable the system to withstandstrong winds and other adverse weather conditions. Also, the anchorssuch as the anchors 34, 36 and 38 enable the system 10 to beconveniently installed in many different locations.

The solar panel array assembly 12 may include a frame 49 (FIG. 2) forholding the plurality of solar panels 13 in a planar configuration. Asshown in FIG. 3, according to one embodiment, fourteen solar panels 13may be fixedly attached to the front of the frame 49 in a typicalconfiguration, but other larger or smaller number of panels may beemployed. The number of solar panels attached to the frame may vary dueto the size or shape of the frame and/or the size of the solar panels.

As best seen in FIGS. 2 and 5, a pair of support beams 52, 54 may befixedly attached to the back of the frame 49 in a parallel, spaced apartmanner. In order to moveably support the array assembly 12 on thestationary support structure 18, a spindle 56 rotatable about its axismay extend between the support beams 52, 54 approximately midway betweenthe top and bottom of the frame 49 and be rotatably connected to eachsupport beam 52, 54 at its ends 58 and 61, respectively, by means of apair of sleeve connectors or bearings 59 and 60 (FIG. 2), respectively,fixed to the support beams 52, 54. In this manner, the assembly 12 canbe moved in a North/South (N/S) inclination to adjust for seasonalchanges.

A gear section 62 may be attached fixedly to a support beam 64 of theframe 49 and rotatably connected to the spindle at point 66 using aconnector 68. The gear section 62 may be driven by the North/South (N/S)motor 70 (FIG. 1) using a gear 85 in communication with the gear section62. The N/S motor 70 (FIG. 1) may be controlled by the trackercontroller 16 (FIG. 1) to pivot controllably the frame 49 with solarpanels 13 in the N/S orientation. The N/S inclinometer 83 (FIG. 1) maybe attached to the frame 49 in a manner to provide feedback to thetracker controller 16 regarding the N/S orientation of the solar panels13. A plurality of support arms 63, 65, 67, 69 may connect the spindle56 to a shaft 72 disposed below the spindle 56 and extendingperpendicularly thereto. The N/S motor 70 (FIG. 1) may be mounted on theshaft 72 using motor support 71.

The shaft 72 may extend between and be rotatably connected to thesupport rods 21, 23, 27, 29, 31 at the opposite ends of the shaft 72 bya pair of bearings such as bearing 33 (FIG. 5) using a pair ofconnectors such as connector 78. A gear section 74 may be fixedly anddrivingly attached to the shaft 72 at point 73. The shaft 72 and gearsection 74 may be driven by then East/West (E/W) motor 75 (FIG. 1) usinga gear 77 meshing with the gear section 74. The E/W motor 75 (FIG. 1)may be controlled by the tracker controller 16 (FIG. 1) to pivot theframe 49 with solar panels 13 in the E/W orientation. The E/Winclinometer 81 (FIG. 1) may be attached to the frame 49 in a manner toprovide feedback to the tracker controller 16 regarding the E/Worientation of the solar panels 13. The E/W motor 75 (FIG. 1) may bemounted on motor support 79 supported by support arms 80, 82, and 84attached to anchors 34, 36, and 38, respectively. Support arms 80, 82,and 84 may be connected together at a point 87.

The frame 49 with solar panels may tilt drivingly controllably north tosouth about the spindle 56 which may be pivotably attached at its endsat points 58 and 61 by means of the pair of sleeve connectors 59 and 60,respectively, fixed to the frame 49. The frame with solar panels mayswing drivingly controllably east to west when the shaft 72 is rotatedabout its ends using the bearings in connectors 76, 78 fixedly attachedto the support rods 21, 23, 27, 29, 31 at points 30, 32, which in turnmoves the spindle 56 by means of the four support arms 63, 65,67, 69connecting the shaft 72 to the spindle 56. The spindle 56 and shaft 72may be oriented perpendicular to one another, so that their axes ofrotation are orthogonal.

The north to south tilting may provide the ability for adjusting thealtitude of solar panels 13 above the horizon. The altitude adjustmentmay be necessary for the solar panels 13 to optimally track incident tothe sun's position throughout the year while collecting incident solarradiation. The east to west tilting may provide the ability foradjusting the position of the solar panels 13 relative to true south,commonly referred to as an azimuth adjustment. The azimuth adjustment ofthe solar panels 13 may be necessary to allow the solar panels 13 totrack incident to the sun's position from the east to the westthroughout the day while collecting incident solar radiation.

The support rods 21, 23, 27, 29, 31 may be of varying lengths dependingon the desired set-up angle of the solar panel array assembly 12 and theslope of the surface to which the solar panel array assembly 12 is beingmounted. Each of the supports rods 21, 23, 27, 29, 31 may connect at oneend to one of the ends 76, 78 of rotating support 72 and at the otherend to one of the anchors 34, 36, 38; for example, the support rod 21 isattached to the anchor 34 and the end 76 of the rotating support 72, andthe support rod 23 is attached to the anchor 34 and the end 78 of therotating support 72. Each pair of support rods attached to the sameanchor may create a V-shaped configuration in connecting to the solarpanel array assembly 12, such as support rods 29 and 31 attached to theanchor 36 as shown in FIG. 4. The support rods may be attached to theanchors and the ends of the rotating support utilizing one or morefasteners, such as bolts and nuts, rivets, or other suitable fasteners.

The support rods, anchors, frame, rotating supports, and support armsmay all be made of a suitable rigid material, such as steel, compositesor other materials.

The method of installing the solar panel array assembly may include thefollowing steps. First, the anchors may be securely attached to themounting surface using the appropriate anchors. Next, the support rodsconnecting the front two anchors and bottom end of the rotating supportof the solar panel array assembly may be attached to the appropriateanchors and end of the rotating support. Then the support rod connectingthe back anchor and the top end of the rotating support of the solarpanel array assembly may be attached to the back anchor and top end ofthe rotating support by maneuvering without lifting the solar panelarray assembly. The solar panel array assembly may then be raised intothe desired position at least partially support by the attached supportrods, and the remaining support rods may now be attached. This supportstructure using a plurality of support rods may be very robust andcapable of withstanding the desired loads.

Referring now to FIGS. 7 and 8, another embodiment of the solar trackersystem of the present invention is shown and generally referenced as100. The solar tracker system 100 may include a solar panel array 102, atetrahedron-type structure 104 connected at two points 106, 108 to thesolar panel array 102, and a ground surface support 111 connection attwo points 113, 115 to the tetrahedron-type structure 104 in astructurally secure manner. The ground surface support 111 may also beconnected to three anchors 117, 119, 122 attached to the ground surfaceor structure.

The solar panel array 102 may be a device for collecting solar radiationand converting the solar radiation to electricity. The solar panel arraymay include an aggregation of individual solar panels fastened in acoplanar manner to a supporting structure.

The two connection points 106, 108 securely attaching the solar panelarray 102 to the tetrahedron-type structure 104 may allow a rotationaldegree of freedom about an axis orthogonal to the solar panel array 102.This rotational degree of freedom about an axis orthogonal to the solarpanel array 102 may provide the ability for adjusting the solar panelarray's 102 altitude above the horizon, which may be necessary for thesolar panel array 102 to track incident to the sun's position throughoutthe year while collecting incident solar radiation.

The tetrahedron-type structure 104 may structurally support the twoconnection points 106, 108 to the solar panel array 102 and the twoconnection points 113, 115 to the ground surface support 111. Themultiple points of connection utilized with the tetrahedron-typestructure 104 may provide sufficient rigidity to withstand the typicalloads applied at the solar panel array 102, such as the dead load of thesolar panel array 102, the live load of possible environmental elementaccumulation, for example, snow or ice, and other typical environmentalconditions, for example, steady winds and wind gusts.

The two connections points 113, 115 securely attaching thetetrahedron-type structure 104 to the ground surface support 111 mayallow a rotational degree of freedom about an axis orthogonal to theline created by the two connection points 106, 108. The rotation degreeof freedom about an axis orthogonal to the line created by the twoconnection points 106, 108 may provide the ability for adjusting thesolar panel array's 102 position relative to true south, commonlyreferred to as an azimuth adjustment. The azimuth adjustment of thesolar panel array 102 may be necessary to allow the solar panel array102 to track incident to the sun's position from the east to the westthroughout the day while collecting incident solar radiation.

The altitude and azimuth adjustments of the solar panel array 102 may beaccomplished in a manner similar to the adjustments of the solar panels13 on frame 49 of the solar tracker system 10.

The ground surface support 111 may structurally support the twoconnection points 113, 115 to the tetrahedron-type structure and connectto the three anchors 117, 119, 122. This configuration may eliminate alldegrees of freedom between the ground surface support 111 and the groundsurface or structure to allow the solar tracker system 100 to withstandthe typical loads described above and functionally operate trackingincident to the sun's position throughout the day and throughout theyear while collection solar radiation.

The anchors 117, 119, and 122 may be as previously described for thesolar tracker system 10, such as ground penetrating fasteners, structurefasteners, or fasteners constrained by blocks of sufficient weight. Eachof the fasteners may constrain the solar tracker system 100 from anydegree of freedom at the ground surface or structure.

Referring now to FIG. 10, still another embodiment of the solar trackersystem of the present invention is shown and generally referenced as200. The solar tracker system 200 may be substantially identical to thesolar tracker system 10 shown in FIGS. 2 through 5 except for itsanchoring mechanism. The solar tracker system 200 may include anattachment point 202, such as ring, disposed at a location substantiallythe same as the point 87 referenced in FIG. 4. Attachment point 202 maybe anchored to the ground 204 or other surface using a ground anchor 206or other suitable anchor. The ground anchor 206 may be connected to theattachment point 202 using a connector 208, such as a cable. Theconnector 208 may further include a tightening device 210, such as aturnbuckle. With the attachment point 202 connected to the ground anchor206 via connector 208, the turnbuckle 210 may be rotated to draw thefeet of the system, such as foot 212, into a firmly planted andimmovable position with the ground 204 and prevent movement of thesystem due to wind gusts. Other connectors may be used to connect theattachment point 202 to the ground anchor 206, such as an individualcable, a chain, or other suitable connector.

Words such as “about,” “approximately” or other such words as usedherein shall be defined to mean a tolerance of plus or minus 20 percent.

While particular embodiments of the present invention have beendisclosed, it is to be understood that various different modificationsare possible and are contemplated within the true spirit and scope ofthe appended claims. For example, while three anchors are disclosed, itis contemplated that a single anchor may be employed and falls withinthe true spirit and scope of the appended claims. There is no intention,therefore, of limitations to the exact abstract or disclosure hereinpresented.

1. A solar tracker system for mounting on a surface, comprising; a solarpanel array assembly having at least two attachments; a support anchorassembly for attaching to the surface and having at least twoattachments; a support structure including a plurality of elongatedsupport rods for securing the array assembly above the support anchorassembly, each support rod attached at one end to one of the attachmentsof the solar panel array and attached at the other end to one of theattachments of the support anchor assembly, wherein the number ofsupport rods connected to each attachment of the solar panel arrayassembly equals the number of attachments of the support anchorassembly, and the number of support rods connected to each attachment ofthe support anchor assembly equals the number of attachments of thesolar panel assembly.
 2. The solar tracker system according to claim 1,wherein the solar panel array includes one or more solar panels forcollecting solar radiation.
 3. The solar tracker system according toclaim 1, wherein the support structure is configured like a tetrahedral.4. The solar tracker system according to claim 1, wherein the solarpanel array assembly includes at least one rotating support.
 5. Thesolar tracker system according to claim 1, wherein the support anchorassembly includes a rotating support.
 6. The solar tracker systemaccording to claim 5, wherein the support anchor assembly includes asupport beam attached to the surface and an anchor attached to thesurface with the rotating support attached at one end to the supportbeam and at the other end to the anchor.
 7. The solar tracker systemaccording to claim 1, further comprising two rotatable supports.
 8. Thesolar tracker system according to claim 7, wherein each of the rotatablesupports includes a gear section.
 9. The solar tracker system accordingto claim 8, further comprising a pair of motors, each motor adapted todrive one of the gear sections.
 10. The solar tracker system accordingto claim 9, further comprising a controller adapted for controlling themotors capable of driving the gear sections.
 11. A solar tracker systemfor mounting on a surface, comprising: a solar panel array assemblyhaving at least two attachments; at least three anchors for attaching tothe surface; a support structure including a plurality of elongatedsupport rods for securing the array assembly above the support anchorassembly, each support rod attached at one end to one of the attachmentsof the solar panel array and attached at the other end to one of theanchors, wherein the number of support rods connected to each attachmentof the solar panel array assembly equals the number of anchors, and thenumber of support rods connected to each anchors equals the number ofattachments of the solar panel assembly.
 12. The solar tracker systemaccording to claim 11, wherein the solar panel array includes one ormore solar panels for collecting solar radiation.
 13. The solar trackersystem according to claim 11, wherein each pair of support rods attachedto the same anchor forms a V-shape in connecting to the solar panelarray assembly.
 14. The solar tracker system according to claim 11,wherein the solar panel array assembly includes a first rotating supportdisposed adjacent to the solar panels and a second rotating supportdisposed adjacent to the support structure.
 15. The solar tracker systemaccording to claim 14, wherein the first rotating support provides analtitude adjustment for tracking the sun's position throughout the year.16. The solar tracker system according to claim 14, wherein the secondrotating support provides an azimuth adjustment for tracking the sun'sposition throughout the day.
 17. The solar tracker system according toclaim 14, further comprising a pair of motors, each motor adapted torotate one of the rotating supports.
 18. The solar tracker systemaccording to claim 14, further comprising a controller for controllingthe motors adapted to rotate the rotating supports.
 19. The solartracker system according to claim 11, wherein the anchors are adapted toattach to the top of a structure.
 20. The solar tracker system accordingto claim 11, wherein the anchor is a helical screw anchor for attachingto the ground.
 21. A solar tracker system for mounting on a surface,comprising; a solar panel array assembly having a rotating support; asupport anchor assembly for attaching to the surface and having arotating support; a support structure disposed between the rotatingsupport of the solar panel array assembly and the rotating support ofthe support anchor assembly, the support structure including a pluralityof elongated support rods configured in the shape of a tetrahedron forsecuring the array assembly above the support anchor assembly.
 22. Thesolar tracker system according to claim 21, wherein the rotating supportof the solar panel array provides an altitude adjustment for trackingthe sun's position throughout the year.
 23. The solar tracker systemaccording to claim 21, wherein the rotating support of the supportanchor assembly provides an azimuth adjustment for tracking the sun'sposition throughout the day.
 24. A solar tracker system for mounting toa surface, comprising: a support structure anchored to the surface; asolar panel array assembly moveably mounted to the support structure ontwo axes of rotation; the support structure including a first rotatingsupport for one of the two axes of rotation; and the solar panel arrayassembly including a second rotating support for the other one of thetwo axes of rotation.
 25. The solar tracker system according to claim24, wherein each of the rotatable supports includes a gear section. 26.The solar tracker system according to claim 25, further comprising apair of motors, each motor adapted to drive one of the gear sections.27. The solar tracker system according to claim 26, further comprising acontroller adapted for controlling the motors capable of driving thegear sections.
 28. A solar tracker system for mounting to an anchor in asurface, comprising: a support structure having at least three legs; asolar panel array assembly mounted to the support structure; ananchoring point disposed on the support structure and adapted forattaching to the anchor in the surface; a connector for attaching theanchoring point to the anchor.
 29. The solar tracker system according toclaim 28, wherein the connector includes a cable.
 30. The solar trackersystem according to claim 28, wherein the connector includes atightening device.
 31. The solar tracker system according to claim 30,wherein the tightening device includes a turnbuckle.